US9376863B2 - High efficiency roller shade - Google Patents

Abstract

A motorized roller shade is provided. The motorized roller shade includes a shade tube in which a motor unit, a controller unit and a power supply unit are disposed. The controller unit includes a controller to control the motor. The power supply unit includes at least one bearing rotatably coupled to a support shaft. The motor unit includes at least one bearing, rotatably coupled to another support shaft, a DC gear motor and a counterbalancing device. The output shaft of the DC gear motor is coupled to the support shaft such that the output shaft and the support shaft do not rotate when the support shaft is attached to a mounting bracket.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No. 13/276,963, filed on Oct. 19, 2011, which is a Continuation-in-Part of U.S. patent application Ser. No. 12/711,192, filed on Feb. 23, 2010 (now U.S. Pat. No. 8,299,734, issued on Oct. 30, 2012), the disclosures of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to a motorized shade. Specifically, the present invention relates to a high-efficiency roller shade.

BACKGROUND OF THE INVENTION

One ubiquitous form of window treatment is the roller shade. A common window covering during the 19^thcentury, a roller shade is simply a rectangular panel of fabric, or other material, that is attached to a cylindrical, rotating tube. The shade tube is mounted near the header of the window such that the shade rolls up upon itself as the shade tube rotates in one direction, and rolls down to cover the a desired portion of the window when the shade tube is rotated in the opposite direction.

A control system, mounted at one end of the shade tube, can secure the shade at one or more positions along the extent of its travel, regardless of the direction of rotation of the shade tube. Simple mechanical control systems include ratchet-and-pawl mechanisms, friction brakes, clutches, etc. To roll the shade up and down, and to position the shade at intermediate locations along its extend of travel, ratchet-and-pawl and friction brake mechanisms require the lower edge of the shade to be manipulated by the user, while clutch mechanisms include a control chain that is manipulated by the user.

Not surprisingly, motorization of the roller shade was accomplished, quite simply, by replacing the simple, mechanical control system with an electric motor that is directly coupled to the shade tube. The motor may be located inside or outside the shade tube, is fixed to the roller shade support and is connected to a simple switch, or, in more sophisticated applications, to a radio frequency (RF) or infrared (IR) transceiver, that controls the activation of the motor and the rotation of the shade tube.

Many known motorized roller shades provide power, such as 120 VAC, 220/230VAC 50/60 Hz, etc., to the motor and control electronics from the facility in which the motorized roller shade is installed. Recently-developed battery-powered roller shades provide installation flexibility by removing the requirement to connect the motor and control electronics to facility power. The batteries for these roller shades are typically mounted within, above, or adjacent to the shade mounting bracket, headrail or fascia. Unfortunately, these battery-powered systems suffer from many drawbacks, including, for example, high levels of self-generated noise, inadequate battery life, inadequate or nonexistent counterbalancing capability, inadequate or nonexistent manual operation capability, inconvenient installation requirements, and the like.

SUMMARY OF THE INVENTION

Embodiments of the present invention advantageously provide a motorized roller shade that includes a shade tube in which a motor unit, a controller unit and a power supply unit are disposed. The controller unit includes a controller to control the motor. The power supply unit includes at least one bearing rotatably coupled to a support shaft. The motor unit includes a bearing, rotatably coupled to another support shaft, a DC gear motor and a counterbalancing device, such as, for example, a rotating perch, a fixed perch and a spring. The output shaft of the DC gear motor is coupled to the support shaft such that the output shaft and the support shaft do not rotate when the support shaft is attached to a mounting bracket.

There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B depict complementary isometric views of a motorized roller shade assembly, in accordance with embodiments of the present invention.

FIGS. 2A and 2B depict complementary isometric views of a motorized roller shade assembly, in accordance with embodiments of the present invention.

FIG. 3 depicts an exploded, isometric view of the motorized roller shade assembly depicted inFIG. 2B.

FIG. 4 depicts an isometric view of a motorized tube assembly, according to one embodiment of the present invention.

FIG. 5 depicts a partially-exploded, isometric view of the motorized tube assembly depicted inFIG. 4.

FIG. 6 depicts an exploded, isometric view of the motor/controller unit depicted inFIG. 5.

FIGS. 7A and 7B depict exploded, isometric views of a motor/controller unit according to an alternative embodiment of the present invention.

FIGS. 7C, 7D and 7E depict isometric views of a motor/controller unit according to another alternative embodiment of the present invention.

FIG. 8A depicts an exploded, isometric view of the power supply unit depicted inFIGS. 4 and 5.

FIG. 8B depicts an exploded, isometric view of a power supply unit according to an alternative embodiment of the present invention.

FIG. 8C depicts an exploded, isometric view of a power supply unit according to an alternative embodiment of the present invention.

FIGS. 9A and 9B depict exploded, isometric views of a power supply unit according to an alternative embodiment of the present invention.

FIG. 10 presents a front view of a motorized roller shade, according to an embodiment of the present invention.

FIG. 11 presents a sectional view along the longitudinal axis of the motorized roller shade depicted inFIG. 10.

FIG. 12 presents a front view of a motorized roller shade, according to an embodiment of the present invention.

FIG. 13 presents a sectional view along the longitudinal axis of the motorized roller shade depicted inFIG. 12.

FIG. 14 presents a front view of a motorized roller shade, according to an embodiment of the present invention.

FIG. 15 presents a sectional view along the longitudinal axis of the motorized roller shade depicted inFIG. 14.

FIG. 16 presents an isometric view of a motorized roller shade assembly in accordance with the embodiments depicted inFIGS. 10-15.

FIG. 17 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an embodiment of the present invention.

FIG. 18 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 17.

FIG. 19 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an embodiment of the present invention.

FIG. 20 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 19.

FIG. 21 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an embodiment of the present invention.

FIG. 22 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 21.

FIG. 23 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an embodiment of the present invention.

FIG. 24 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 23.

FIG. 25 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an embodiment of the present invention.

FIG. 26 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 25.

FIG. 27 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an alternative embodiment of the present invention.

FIG. 28 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 27.

FIG. 29 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an alternative embodiment of the present invention.

FIG. 30 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 29.

FIG. 31 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an alternative embodiment of the present invention.

FIG. 32 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 31.

FIG. 33 presents a partially-exploded, isometric view of a motorized roller shade with counterbalancing, according to an alternative embodiment of the present invention.

FIG. 34 presents a sectional view along the longitudinal axis of the embodiment depicted inFIG. 33.

FIG. 35 presents amethod400 for controlling amotorized roller shade20, according to an embodiment of the present invention.

FIGS. 36-45 present operational flow charts illustrating various preferred embodiments of the present invention.

DETAILED DESCRIPTION

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. The term “shade” as used herein describes any flexible material, such as a shade, a curtain, a screen, etc., that can be deployed from, and retrieved onto, a storage tube.

Embodiments of the present invention provide a remote controlled motorized roller shade in which the batteries, DC gear motor, control circuitry are entirely contained within a shade tube that is supported by bearings. Two support shafts are attached to respective mounting brackets, and the bearings rotatably couple the shade tube to each support shaft. The output shaft of the DC gear motor is fixed to one of the support shafts, while the DC gear motor housing is mechanically coupled to the shade tube. Accordingly, operation of the DC gear motor causes the motor housing to rotate about the fixed DC gear motor output shaft, which causes the shade tube to rotate about the fixed DC gear motor output shaft as well. Because these embodiments do not require external wiring for power or control, great flexibility in mounting, and re-mounting, the motorized roller shade is provided.

Encapsulation of the motorization and control components within the shade tube, combined with the performance of the bearings and enhanced battery capacity of the DC gear motor configuration described above, greatly increases the number of duty cycles provided by a single set of batteries and provides a highly efficient roller shade. Additionally, encapsulation advantageously prevents dust and other contaminants from entering the electronics and the drive components.

In an alternative embodiment, the batteries may be mounted outside of the shade tube, and power may be provided to the components located within the shade tube using commutator or slip rings, induction techniques, and the like. Additionally, the external batteries may be replaced by any external source of DC power, such as, for example, an AC/DC power converter, a solar cell, etc.

FIGS. 1A and 1B depict complementary isometric views of a motorizedroller shade assembly10 having a reverse payout, in accordance with embodiments of the present invention.FIGS. 2A and 2B depict complementary isometric views of a motorizedroller shade assembly10 having a standard payout, in accordance with embodiments of the present invention, whileFIG. 3 depicts an exploded, isometric view of the motorizedroller shade assembly10 depicted inFIG. 2B. In one embodiment,motorized roller shade20 is mounted near the top portion of a window, door, etc., using mountingbrackets5 and7. In another embodiment,motorized roller shade20 is mounted near the top portion of the window using mountingbrackets15 and17, which also supportfascia12. In the latter embodiment, fascia end caps14 and16 attach to fascia12 to concealmotorized roller shade20, as well as mountingbrackets15 and17.

Generally,motorized roller shade20 includes ashade22 and amotorized tube assembly30. In a preferred embodiment,motorized roller shade20 also includes abottom bar28 attached to the bottom ofshade22. In one embodiment,bottom bar28 provides an end-of-travel stop, while in an alternative embodiment, end-of-travel stops24 and26 may be provided. As discussed in more detail below, in preferred embodiments, all of the components necessary to power and control the operation of themotorized roller shade20 are advantageously located withinmotorized tube assembly30.

FIGS. 4 and 5 depict isometric views ofmotorized tube assembly30, according to one embodiment of the present invention.Motorized tube assembly30 includes ashade tube32, motor/controller unit40 andpower supply unit80. The top ofshade22 is attached to the outer surface ofshade tube32, while motor/controller unit40 andpower supply unit80 are located within an inner cavity defined by the inner surface ofshade tube32.

FIG. 6 depicts an exploded, isometric view of the motor/controller unit40 depicted inFIG. 5. Generally, the motor/controller unit40 includes anelectrical power connector42, a circuit board housing44, aDC gear motor55 that includes aDC motor50 and an integral motorgear reducing assembly52, a mount54 for theDC gear motor55, and a bearinghousing58.

Theelectrical power connector42 includes a terminal41 that couples to thepower supply unit80, andpower cables43 that connect to the circuit board(s) located within the circuit board housing44.Terminal41 includes positive and negative connectors that mate with cooperating positive and negative connectors ofpower supply unit80, such as, for example, plug connectors, blade connectors, a coaxial connector, etc. In a preferred embodiment, the positive and negative connectors do not have a preferred orientation. Theelectrical power connector42 is mechanically coupled to the inner surface of theshade tube32 using a press fit, an interference fit, a friction fit, a key, adhesive, etc.

The circuit board housing44 includes an end cap45 and a housing body46 within which at least onecircuit board47 is mounted. In the depicted embodiment, twocircuit boards47 are mounted within the circuit board housing44 in an orthogonal relationship.Circuit boards47 generally include all of the supporting circuitry and electronic components necessary to sense and control the operation of themotor50, manage and/or condition the power provided by thepower supply unit80, etc., including, for example, a controller or microcontroller, memory, a wireless receiver, etc. In one embodiment, the microcontroller is an Microchip 8-bit microcontroller, such as the PIC18F25K20, while the wireless receiver is a Micrel QwikRadio® receiver, such as the MICRF219. The microcontroller may be coupled to the wireless receiver using a local processor bus, a serial bus, a serial peripheral interface, etc. In another embodiment, the wireless receiver and microcontroller may be integrated into a single chip, such as, for example, the Zensys ZW0201 Z-Wave Single Chip, etc.

The antenna for the wireless receiver may be mounted to the circuit board or located, generally, inside the circuit board housing44. Alternatively, the antenna may be located outside the circuit board housing44, including, for example, the outer surface of the circuit board housing44, the inner surface of theshade tube32, the outer surface of theshade tube32, the bearinghousing58, etc. In a further embodiment, at least a portion of the outer surface of theshade tube32 may act as the antenna. The circuit board housing44 may be mechanically coupled to the inner surface of theshade tube32 using, for example, a press fit, an interference fit, a friction fit, a key, adhesive, etc.

In another embodiment, a wireless transmitter is also provided, and information relating to the status, performance, etc., of themotorized roller shade20 may be transmitted periodically to a wireless diagnostic device, or, preferably, in response to a specific query from the wireless diagnostic device. In one embodiment, the wireless transmitter is a Micrel QwikRadio® transmitter, such as the MICRF102. A wireless transceiver, in which the wireless transmitter and receiver are combined into a single component, may also be included, and in one embodiment, the wireless transceiver is a Micrel Radio Wire® transceiver, such as the MICRF506. In another embodiment, the wireless transceiver and microcontroller may be integrated into a single module, such as, for example, the Zensys ZM3102 Z-Wave Module, etc. The functionality of the microcontroller, as it relates to the operation of themotorized roller shade20, is discussed in more detail below.

In an alternative embodiment, theshade tube32 includes one or more slots to facilitate the transmission of wireless signal energy to the wireless receiver, and from the wireless transmitter, if so equipped. For example, if the wireless signal is within the radio frequency (RF) band, the slot may be advantageously matched to the wavelength of the signal. For one RF embodiment, the slot is ⅛″ wide and 2½″ long; other dimensions are also contemplated.

TheDC motor50 is electrically connected to thecircuit board47, and has an output shaft that is connected to the input shaft of the motorgear reducing assembly52. TheDC motor50 may also be mechanically coupled to the circuit board housing body46 using, for example, a press fit, an interference fit, a friction fit, a key, adhesive, mechanical fasteners, etc. In various embodiments of the present invention,DC motor50 and motorgear reducing assembly52 are provided as a single mechanical package, such as the DC gear motors manufactured by Bühler Motor Inc.

In one preferred embodiment,DC gear motor55 includes a 24V DC motor and a two-stage planetary gear system with a 40:1 ratio, such as, for example, Bühler DC Gear Motor 1.61.077.423, and is supplied with an average battery voltage of 9.6V_avgprovided by an eight D-cell battery stack. Other alternative embodiments are also contemplated by the present invention. However, this preferred embodiment offers particular advantages over many alternatives, including, for example, embodiments that include smaller average battery voltages, smaller battery sizes, 12V DC motors, three-stage planetary gear systems, etc.

For example, in this preferred embodiment, the 24VDC gear motor55 draws a current of about 0.1 A when supplied with a battery voltage of 9.6V_avg. However, under the same torsional loading and output speed (e.g., 30 rpm), a 12V DC gear motor with a similar gear system, such as, e.g., Bühler DC Gear Motor 1.61.077.413, will draw a current of about 0.2 A when supplied with a battery voltage of 4.8V_avg. Assuming similar motor efficiencies, the 24V DC gear motor supplied with 9.6V_avgadvantageously draws about 50% less current than the 12V DC gear motor supplied with 4.8V_avgwhile producing the same power output.

In one embodiment, theDC gear motor55 includes a 24V DC motor and a two-stage planetary gear system with a 40:1 ratio, while the operating voltage is provided by a six cell battery stack. In another embodiment, theDC gear motor55 includes a 24V DC motor and a two-stage planetary gear system with a 22:1 ratio, while the operating voltage is provided by a four cell battery stack; counterbalancing is also provided.

In preferred embodiments of the present invention, the rated voltage of the DC gear motor is much greater than the voltage produced by the batteries, by a factor of two or more, for example, causing the DC motor to operate at a reduced speed and torque rating, which advantageously eliminates undesirable higher frequency noise and draws lower current from the batteries, thereby improving battery life. In other words, applying a lower-than-rated voltage to the DC gear motor causes the motor to run at a lower-than-rated speed to produce quieter operation and longer battery life as compared to a DC gear motor running at its rated voltage, which draws similar amperage while producing lower run cycle times to produce equivalent mechanical power. In the embodiment described above, the 24V DC gear motor, running at lower voltages, enhances the cycle life of the battery operated roller shade by about 20% when compared to a 12V DC gear motor using the same battery capacity. Alkaline, zinc and lead acid batteries may provide better performance than lithium or nickel batteries, for example.

In another example, four D-cell batteries produce an average battery voltage of about 4.8V_avg, while eight D-cell batteries produce an average battery voltage of about 9.6V_avg. Clearly, embodiments that include an eight D-cell battery stack advantageously provide twice as much battery capacity than those embodiments that include a four D-cell battery stack. Of course, smaller battery sizes, such as, e.g., C-cell, AA-cell, etc., offer less capacity than D-cells.

In a further example, supplying a 12V DC gear motor with 9.6V_avgincreases the motor operating speed, which requires a higher gear ratio in order to provide the same output speed as the 24V DC gear motor discussed above. In other words, assuming the same torsional loading, output speed (e.g., 30 rpm) and average battery voltage (9.6V_avg), the motor operating speed of the 24V DC gear motor will be about 50% of the motor operating speed of the 12V DC gear motor. The higher gear ratio typically requires an additional planetary gear stage, which reduces motor efficiency, increases generated noise, reduces backdrive performance and may require a more complex motor controller. Consequently, those embodiments that include a 24V DC gear motor supplied with 9.6V_avgoffer higher efficiencies and less generated noise.

In one embodiment, theshaft51 ofDC motor50 protrudes into the circuit board housing44, and amulti-pole magnet49 is attached to the end of themotor shaft51. A magnetic encoder (not shown for clarity) is mounted on thecircuit board47 to sense the rotation of themulti-pole magnet49, and outputs a pulse for each pole of themulti-pole magnet49 that moves past the encoder. In a preferred embodiment, themulti-pole magnet49 has eight poles and thegear reducing assembly52 has a gear ratio of 30:1, so that the magnetic encoder outputs 240 pulses for each revolution of theshade tube32. The controller advantageously counts these pulses to determine the operational and positional characteristics of the shade, curtain, etc. Other types of encoders may also be used, such as optical encoders, mechanical encoders, etc.

The number of pulses output by the encoder may be associated with a linear displacement of theshade22 by a distance/pulse conversion factor or a pulse/distance conversion factor. In one embodiment, this conversion factor is constant regardless of the position ofshade22. For example, using the outer diameter d of theshade tube32, e.g., 1⅝ inches (1.625 inches), each rotation of theshade tube32 moves the shade22 a linear distance of π*d, or about 5 inches. For the eight-pole magnet49 and 30:1gear reducing assembly52 embodiment discussed above, the distance/pulse conversion factor is about 0.02 inches/pulse, while the pulse/distance conversion factor is about 48 pulses/inch. In another example, the outer diameter of the fully-wrappedshade22 may be used in the calculation. When a length ofshade22 is wrapped onshade tube32, such as 8 feet, the outer diameter of the wrappedshade22 depends upon the thickness of the shade material. In certain embodiments, the outer diameter of the wrappedshade22 may be as small as 1.8 inches or as large as 2.5 inches. For the latter case, the distance/pulse conversion factor is about 0.03 inches/pulse, while the pulse/distance conversion factor is about 30 pulses/inch. Of course, any diameter between these two extremes, i.e., the outer diameter of theshade tube32 and the outer diameter of the wrappedshade22, may be used. These approximations generate an error between the calculated linear displacement of the shade and the true linear displacement of the shade, so an average or intermediate diameter may preferably reduce the error. In another embodiment, the conversion factor may be a function of the position of theshade22, so that the conversion factor depends upon the calculated linear displacement of theshade22.

In various preferred embodiments discussed below, the position of theshade22 is determined and controlled based on the number of pulses that have been detected from a known position ofshade22. While the open position is preferred, the closed position may also be used as the known position. In order to determine the full range of motion ofshade22, for example, the shade may be electrically moved to the open position, an accumulated pulse counter may be reset and theshade22 may then be moved to the closed position, manually and/or electrically. The total number of accumulated pulses represents the limit of travel for the shade, and any desirable intermediate positions may be calculated based on this number.

For example, an 8 foot shade that moves from the open position to the closed position may generate 3840 pulses, and various intermediate positions of theshade22 can be advantageously determined, such as, 25% open, 50% open, 75% open, etc. Quite simply, the number of pulses between the open position and the 75% open position would be 960, the number of pulses between the open position and the 50% open position would be 1920, and so on. Controlled movement between these predetermined positions is based on the accumulated pulse count. For example, at the 50% open position, this 8 foot shade would have an accumulated pulse count of 1920, and controlled movement to the 75% open position would require an increase in the accumulated pulse count to 2880. Accordingly, movement of theshade22 is determined and controlled based on accumulating the number of pulses detected since theshade22 was deployed in the known position. An average number of pulses/inch may be calculated based on the total number of pulses and the length ofshade22, and an approximate linear displacement of theshade22 can be calculated based on the number of pulses accumulated over a given time period. In this example, the average number of pulses/inch is 40, so movement of theshade22 about 2 inches would generate about 80 pulses. Positional errors are advantageously eliminated by resetting the accumulated pulse counter to zero whenever theshade22 is moved to the known position.

A mount54 supports theDC gear motor55, and may be mechanically coupled to the inner surface of theshade tube32. In one embodiment, the outer surface of the mount54 and the inner surface of theshade tube32 are smooth, and the mechanical coupling is a press fit, an interference fit, a friction fit, etc. In another embodiment, the outer surface of the mount54 includes several raised longitudinal protrusions that mate with cooperating longitudinal recesses in the inner surface of theshade tube32. In this embodiment, the mechanical coupling is keyed; a combination of these methods is also contemplated. If the frictional resistance is small enough, the motor/controller unit40 may be removed from theshade tube32 for inspection or repair; in other embodiments, the motor/controller unit40 may be permanently secured within theshade tube32 using adhesives, etc.

As described above, the circuit board housing44 and the mount54 may be mechanically coupled to the inner surface of theshade tube32. Accordingly, at least three different embodiments are contemplated by the present invention. In one embodiment, the circuit board housing44 and the mount54 are both mechanically coupled to the inner surface of theshade tube32. In another embodiment, only the circuit board housing44 is mechanically coupled to the inner surface of theshade tube32. In a further embodiment, only the mount54 is mechanically coupled to the inner surface of theshade tube32.

The output shaft of theDC gear motor55 is fixed to thesupport shaft60, either directly (not shown for clarity) or through anintermediate shaft62. When themotorized roller shade20 is installed,support shaft60 is attached to a mounting bracket that prevents thesupport shaft60 from rotating. Because (a) the output shaft of theDC gear motor55 is coupled to thesupport shaft60 which is fixed to the mounting bracket, and (b) theDC gear motor55 is mechanically-coupled to the shade tube, operation of theDC gear motor55 causes theDC gear motor55 to rotate about the fixed output shaft, which causes theshade tube32 to rotate about the fixed output shaft as well.

Bearinghousing58 includes one ormore bearings64 that are rotatably coupled to thesupport shaft60. In a preferred embodiment, bearinghousing58 includes two rolling element bearings, such as, for example, spherical ball bearings; each outer race is attached to the bearinghousing58, while each inner race is attached to thesupport shaft60. In a preferred embodiment, two ball bearings are spaced about ⅜″ apart giving a total support land of about 0.8″ or 20 mm; in an alternative embodiment, the intra-bearing spacing is about twice the diameter ofsupport shaft60. Other types of low-friction bearings are also contemplated by the present invention.

The motor/controller unit40 may also include counterbalancing. In a preferred embodiment, motor/controller unit40 includes a fixedperch56 attached tointermediate shaft62. In this embodiment, mount54 functions as a rotating perch, and a counterbalance spring63 (not shown inFIG. 5 for clarity; shown inFIG. 6) is attached to the rotating perch54 and the fixedperch56. Theintermediate shaft62 may be hexagonal in shape to facilitate mounting of the fixedperch56. Preloading the counterbalance spring advantageously improves the performance of themotorized roller shade20.

FIGS. 7A and 7B depict exploded, isometric views of a motor/controller unit40 according to an alternative embodiment of the present invention. In this embodiment,housing67 contains the major components of the motor/controller unit40, including DC gear motor55 (e.g.,DC motor50 and motor gear reducing assembly52), one ormore circuit boards47 with the supporting circuitry and electronic components described above, and at least onebearing64. Theoutput shaft53 of theDC gear motor55 is fixedly-attached to thesupport shaft60, while the inner race of bearing64 is rotatably-attachedsupport shaft60. In one counterbalance embodiment, at least onepower spring65 is disposed withinhousing67, and is rotatably-attached to supportshaft60.Housing67 may be formed from two complementary sections, fixed or removably joined by one or more screws, rivets, etc.

FIGS. 7C, 7D and 7E depict isometric views of a motor/controller unit40 according to another alternative embodiment of the present invention. In this embodiment,housing68 contains the DC gear motor55 (e.g.,DC motor50 and motor gear reducing assembly52), one ormore circuit boards47 with the supporting circuitry and electronic components described above, whilehousing69 includes at least onebearing64.Housings68 and69 may be attachable to one another, either removably or permanently. Theoutput shaft53 of theDC gear motor55 is fixedly-attached to thesupport shaft60, while the inner race of bearing64 is rotatably-attachedsupport shaft60. In one counterbalance embodiment, at least onepower spring65 is disposed withinhousing69, and is rotatably-attached to supportshaft60. While the depicted embodiment includes two power springs65, three (or more) power springs65 may be used, depending on the counterbalance force required, the available space withinshade tube32, etc.Housings68 and69 may be formed from two complementary sections, fixed or removably joined by one or more screws, rivets, etc.

FIG. 8A depicts an exploded, isometric view of thepower supply unit80 depicted inFIGS. 4 and 5. Generally, thepower supply unit80 includes abattery tube82, anouter end cap86, and ainner end cap84. Theouter end cap86 includes one ormore bearings90 that are rotatably coupled to asupport shaft88. In a preferred embodiment,outer end cap86 includes two low-friction rolling element bearings, such as, for example, spherical ball bearings, separated by aspacer91; each outer race is attached to theouter end cap86, while each inner race is attached to thesupport shaft88. Other types of low-friction bearings are also contemplated by the present invention. In one alternative embodiment,bearings86 are simply bearing surfaces, preferably low-friction bearing surfaces, while in another alternative embodiment,support shaft88 is fixedly attached to theouter end cap86, and the external shade support bracket provides the bearing surface for thesupport shaft88.

In the depicted embodiment, theouter end cap86 is removable and theinner cap84 is fixed. In other embodiments, theinner end cap84 may be removable and theouter end cap86 may be fixed, both end caps may be removable, etc. The removable end cap(s) may be threaded, slotted, etc.

Theouter end cap86 also includes a positive terminal that is coupled to thebattery tube82. Theinner end cap84 includes a positive terminal coupled to thebattery tube82, and a negative terminal coupled to aconduction spring85. When abattery stack92, including at least one battery, is installed in thebattery tube82, the positive terminal of theouter end cap86 is electrically coupled to the positive terminal of one of the batteries in thebattery stack92, and the negative terminal of theinner end cap84 is electrically coupled to the negative terminal of another one of the batteries in thebattery stack92. Of course, the positive and negative terminals may be reversed, so that theconduction spring85 contacts the positive terminal of one of the batteries in thebattery stack92, etc.

Theouter end cap86 and theinner end cap84 are mechanically coupled to the inner surface of theshade tube32. In one embodiment, the outer surface of themount84 and the inner surface of theshade tube32 are smooth, and the mechanical coupling is a press fit, an interference fit, a friction fit, etc. In another embodiment, the outer surface of themount84 includes several raised longitudinal protrusions that mate with cooperating longitudinal recesses in the inner surface of theshade tube32. In this embodiment, the mechanical coupling is keyed; a combination of these methods is also contemplated. Importantly, the frictional resistance should be small enough such that thepower supply unit80 can be removed from theshade tube32 for inspection, repair and battery replacement.

In a preferred embodiment, thebattery stack92 includes eight D-cell batteries connected in series to produce an average battery stack voltage of 9.6V_avg. Other battery sizes, as well as other DC power sources disposable withinbattery tube82, are also contemplated by the present invention.

After the motor/controller unit40 andpower supply unit80 are built up as subassemblies, final assembly of themotorized roller shade20 is quite simple. Theelectrical connector42 is fitted within the inner cavity ofshade tube32 to a predetermined location;power cables43 has a length sufficient to permit the remaining sections of the motor/controller unit40 to remain outside theshade tube32 until theelectrical connector42 is properly seated. The remaining sections of the motor/controller unit40 are then fitted within the inner cavity ofshade tube32, such that the bearinghousing58 is approximately flush with the end of theshade tube32. Thepower supply unit80 is then inserted into the opposite end until the positive and negative terminals of theinner end cap84 engage theterminal41 of theelectrical connector42. Theouter end cap86 should be approximately flush with end of theshade tube32.

In the alternative embodiment depicted inFIG. 8B, theouter end cap86 is mechanically coupled to the inner surface of theshade tube32 using a press fit, interference fit, an interference member, such as O-ring89, etc., while theinner end cap81 is not mechanically coupled to the inner surface of theshade tube32.

In the alternative embodiment depicted inFIG. 8C, theshade tube32 functions as thebattery tube82, and thebattery stack92 is simply inserted directly intoshade tube32 until one end of thebattery stack92 abuts theinner end cap84. The positive terminal of theouter end cap86 is coupled to the positive terminal of theinner end cap84 using a wire, foil strip, trace, etc. Of course, the positive and negative terminals may be reversed, so that the respective negative terminals are coupled.

In a further alternative embodiment, the batteries may be mounted outside of the shade tube, and power may be provided to the components located within the shade tube using commutator or slip rings, induction techniques, and the like. Additionally, the external batteries may be replaced by any external source of DC power, such as, for example, an AC/DC power converter, a solar cell, etc.

FIGS. 9A and 9B depict exploded, isometric views of a power supply unit according to an alternative embodiment of the present invention. In this embodiment,power supply unit80 includes ahousing95 with one ormore bearings90 that are rotatably coupled to asupport shaft88, apower coupling93 to receive power from an external power source, and positive and negative terminals to engage theelectrical connector42. Power cables97 (shown in phantom for clarity) extend from thepower coupling93, through a hollow central portion ofsupport shaft88, to an external DC power source. In a preferred embodiment,housing95 includes two low-friction rollingelement bearings90, such as, for example, spherical ball bearings; each outer race is attached to thehousing95, while each inner race is attached to thesupport shaft88. Other types of low-friction bearings are also contemplated by the present invention.Housing95 may be formed from two complementary sections, fixed or removably joined by one or more screws, rivets, etc.

In one embodiment, thesupport shafts88 are slidingly-attached to the inner race ofball bearings90 so that thesupport shafts88 may be displaced along the rotational axis of theshade tube32. This adjustability advantageously allows an installer to precisely attach the end of thesupport shafts88 to the respective mounting bracket by adjusting the length of the exposed portion of thesupport shafts88. In a preferred embodiment,outer end cap86 andhousing95 may provide approximately 0.5″ of longitudinal movement for thesupport shafts88. Additionally, mountingbrackets5,7,15 and17 are embossed so that the protruding portion of the mounting bracket will only contact the inner race ofbearings64 and90 and will not rub against the edge of the shade or theshade tube32 if themotorized roller shade20 is installed incorrectly. In a preferred embodiment, the bearings may accommodate up to 0.125″ of misalignment due to installation errors without a significant reduction in battery life.

In an alternative embodiment, the microcontroller receives control signals from a wired remote control. These control signals may be provided to the microcontroller in various ways, including, for example, overpower cables97, over additional signal lines that are accommodated bypower coupling93, over additional signal lines that are accommodated by a control signal coupling (not shown inFIGS. 9A,B for clarity), etc.

Further embodiments of the present invention are presented inFIGS. 10-34.

FIGS. 10 and 11 depict an alternative embodiment of the present invention without counterbalancing.FIG. 10 presents a front view of amotorized roller shade120, whileFIG. 11 presents a sectional view along the longitudinal axis of themotorized roller shade120. In this embodiment, the output shaft of theDC gear motor150 is attached directly to thesupport shaft160, and an intermediate shaft is not included. Advantageously, the one or both of the mounting brackets may function as an antenna.

FIGS. 12 and 13 depict an alternative embodiment of the present invention with counterbalancing.FIG. 12 presents a front view of amotorized roller shade220, whileFIG. 13 presents a sectional view along the longitudinal axis of themotorized roller shade220. In this embodiment, the output shaft of theDC gear motor250 is attached to theintermediate shaft262, and a counterbalance spring (not shown for clarity)couples rotating perch254 to fixedperch256.

FIGS. 14 and 15 depict an alternative embodiment of the present invention with counterbalancing;FIG. 14 presents a front view of amotorized roller shade320, whileFIG. 15 presents a sectional view along the longitudinal axis of themotorized roller shade320. In this embodiment, the output shaft of theDC gear motor350 is attached to theintermediate shaft362. Apower spring390 couples theintermediate shaft362 to the inner surface of the shade tube332.

FIG. 16 presents an isometric view of amotorized roller shade120,220,320, etc., in accordance with the embodiments depicted inFIGS. 10-15 and 17-34.

FIGS. 17 and 18 depict an embodiment of the present invention, with counterbalancing, that is substantially the same as the embodiment depicted inFIGS. 4, 5, 6, 8A, 8B, and 8C, but reversed in orientation.FIG. 17 presents a partially-exploded, isometric view of amotorized roller shade520, whileFIG. 18 presents a sectional view along the longitudinal axis.Motorized roller shade520 includesshade tube532 with anoptional slot533 to facilitate wireless signal transmission, amotor unit570, acontroller unit575 and apower supply unit580. Generally, themotor unit570 includes aDC gear motor555 with aDC motor550 and an integral motorgear reducing assembly552, a mount orrotating perch554 for theDC gear motor555, and anend cap558 housing one ormore bearings564, while thecontroller unit575 includes anelectrical power connector542 and acircuit board housing544;power supply unit580 includes the battery stack and one ormore bearings590. The output shaft of theDC gear motor555 is mechanically coupled to the fixedsupport shaft560 through theintermediate support shaft562, and acounterbalance spring565couples rotating perch554 to fixedperch556. Accordingly, during operation, the output shaft of theDC gear motor555 remains stationary, while the housing of theDC gear motor555 rotates with theshade tube532.Bearings564 are rotationally-coupled to supportshaft560, whilebearings590 are rotationally-coupled to supportshaft588.

FIGS. 19 and 20 depict an embodiment of the present invention, with counterbalancing, that is similar to the embodiment depicted inFIGS. 17 and 18.FIG. 19 presents a partially-exploded, isometric view of amotorized roller shade620, whileFIG. 20 presents a sectional view along the longitudinal axis.Motorized roller shade620 includesshade tube632 with aslot633 to facilitate wireless signal transmission, amotor unit670, acontroller unit675 and apower supply unit680. Generally, themotor unit670 includes aDC gear motor655 with aDC motor650 and an integral motor gear reducing assembly652, a mount orrotating perch654 for theDC gear motor655, and anend cap658 housing one ormore bearings664, while thecontroller unit675 includes acircuit board housing644 and anend cap686housing bearings690. The output shaft of theDC gear motor655 is mechanically coupled to the fixedsupport shaft660 through theintermediate support shaft662, and acounterbalance spring665couples rotating perch654 to fixedperch656. Accordingly, during operation, the output shaft of theDC gear motor655 remains stationary, while the housing of theDC gear motor655 rotates with theshade tube632.Bearings664 are rotationally-coupled to supportshaft660, whilebearings690 are rotationally-coupled to supportshaft688.

FIGS. 21 and 22 depict an embodiment of the present invention with counterbalancing.FIG. 21 presents a partially-exploded, isometric view of amotorized roller shade720, whileFIG. 22 presents a sectional view along the longitudinal axis.Motorized roller shade720 includesshade tube732 with aslot733 to facilitate wireless signal transmission, amotor unit770, acontroller unit775 and apower supply unit780. Generally, themotor unit770 includes aDC gear motor755 with aDC motor750 and an integral motorgear reducing assembly752, amount754 for the DC gear motor, and an end cap758 housing one ormore bearings764, while thecontroller unit775 includes acircuit board housing744, one or more power springs792 (three are depicted), and anend cap786 housing one ormore bearings790. The power springs792 are coupled to the fixedsupport shaft788 and the inner surface of theshade tube732, or, alternatively, thecircuit board housing744. The output shaft of theDC gear motor755 is mechanically coupled to the fixedsupport shaft760. Accordingly, during operation, the output shaft of theDC gear motor755 remains stationary, while the housing of theDC gear motor755, thecontroller unit775 and thepower supply unit780 rotate with theshade tube732.Bearings764 are rotationally-coupled to supportshaft760, whilebearings790 are rotationally-coupled to supportshaft788.

FIGS. 23 and 24 depict an embodiment of the present invention, with counterbalancing, that is similar to the embodiment depicted inFIGS. 17 and 18.FIG. 23 presents a partially-exploded, isometric view of amotorized roller shade820, whileFIG. 24 presents a sectional view along the longitudinal axis.Motorized roller shade820 includesshade tube832 with aslot833 to facilitate wireless signal transmission, amotor unit870, acontroller unit875 and apower supply unit880. Generally, themotor unit870 includes aDC gear motor855 with aDC motor850 and an integral motorgear reducing assembly852, while thecontroller unit875 includes acircuit board housing844, a mount orrotating perch854, and anend cap858 housing one ormore bearings864;power supply unit880 includes the battery stack and one ormore bearings890. The output shaft of theDC gear motor855 is mechanically coupled to the fixedsupport shaft860 through theintermediate support shaft862, and acounterbalance spring865couples rotating perch854 to fixedperch856. Accordingly, during operation, the output shaft of theDC gear motor855 remains stationary, while the housing of theDC gear motor855 rotates with theshade tube832.Bearings864 are rotationally-coupled to supportshaft860, whilebearings890 are rotationally-coupled to supportshaft888.

FIGS. 25 and 26 depict one preferred embodiment of the present invention with counterbalancing.FIG. 25 presents a partially-exploded, isometric view of amotorized roller shade920, whileFIG. 26 presents a sectional view along the longitudinal axis.Motorized roller shade920 includesshade tube932 with aslot933 to facilitate wireless signal transmission, amotor unit970, acontroller unit975 and apower supply unit980. Generally, themotor unit970 includes aDC gear motor955 with aDC motor950 and an integral motorgear reducing assembly952, amount954 for the DC gear motor, and anend cap958 housing one ormore bearings964, while thecontroller unit975 includes acircuit board housing944. Thepower unit980 includes the battery stack, one or more power springs992 (three are depicted) and anend cap986 housing one ormore bearings990. The power springs992 are coupled to the fixedsupport shaft988 and the inner surface of the shade tube932 (as depicted), or, alternatively, to the battery stack. The output shaft of theDC gear motor955 is mechanically coupled to the fixedsupport shaft960. Accordingly, during operation, the output shaft of theDC gear motor955 remains stationary, while the housing of theDC gear motor955, thecontroller unit975 and thepower supply unit980 rotate with theshade tube932.Bearings964 are rotationally-coupled to supportshaft960, whilebearings990 are rotationally-coupled to supportshaft988.

Alternative embodiments of the present invention are depicted inFIGS. 27-34. In contrast to the embodiments depicted inFIGS. 1-26, the output shaft of the DC gear motor is not mechanically coupled to the fixed support shaft. Instead, in these alternative embodiments, the output shaft of the DC gear motor is mechanically coupled to the shade tube, and the housing of the DC gear motor is mechanically coupled to one of the fixed support shafts, so that the housing of the DC gear motor remains stationary while the output shaft rotates with the shade tube.

FIGS. 27 and 28 depict an alternative embodiment of the present invention with counterbalancing.FIG. 27 presents a partially-exploded, isometric view of amotorized roller shade1020, whileFIG. 28 presents a sectional view along the longitudinal axis.Motorized roller shade1020 includesshade tube1032 with aslot1033 to facilitate wireless signal transmission, a motor/controller unit1040, acounterbalancing unit1074 and apower supply unit1080. Generally, the motor/controller unit1040 includes aDC gear motor1055 with aDC motor1050 and an integral motorgear reducing assembly1052, acircuit board housing1044 and atorque transfer coupling1072 attached to the output shaft of theDC gear motor1055 and theshade tube1032. Thecounterbalancing unit1074 includes arotating perch1054 mechanically coupled to theshade tube32, a fixedperch1056 attached to the fixedsupport shaft1060, and acounterbalance spring1065 that couples therotating perch1054 to the fixedperch1056.End cap1058, housing one ormore bearings1064, andend cap1086, housing one ormore bearings1090, are also attached to theshade tube1032. Thepower supply unit1080 includes the battery stack, and is attached to the fixedsupport shaft1088. Importantly, thepower supply unit1080 is also attached to the motor/controller unit1040. Accordingly, during operation, the output shaft of theDC gear motor1055 rotates with theshade tube1032, while both the motor/controller unit1040 andpower supply unit1080 remain stationary.Bearings1064 are rotationally-coupled to supportshaft1060, whilebearings1090 are rotationally-coupled to supportshaft1088.

FIGS. 29 and 30 depict an alternative embodiment of the present invention with counterbalancing.FIG. 29 presents a partially-exploded, isometric view of amotorized roller shade1120, whileFIG. 30 presents a sectional view along the longitudinal axis.Motorized roller shade1120 includes ashade tube1132 with aslot1133 to facilitate wireless signal transmission, a motor/controller unit1140, and apower supply unit1180. Generally, the motor/controller unit1140 includes aDC gear motor1155 with aDC motor1150 and an integral motorgear reducing assembly1152, acircuit board housing1144, atorque transfer coupling1173 that is attached to the output shaft of theDC gear motor1155 and theshade tube1132, and that also functions as a rotating perch, a fixedperch1156 attached to theDC gear motor1155, and acounterbalance spring1165 that couples the rotating perch/torque transfer coupling1173 to the fixedperch1156.End cap1158, housing one ormore bearings1164, andend cap1186, housing one ormore bearings1190, are also attached to theshade tube1132. Thepower supply unit1180 includes the battery stack, and is attached to the fixedsupport shaft1188. Importantly, thepower supply unit1180 is also attached to the motor/controller unit1140. Accordingly, during operation, the output shaft of theDC gear motor1155 rotates with theshade tube1132, while both the motor/controller unit1140 andpower supply unit1180 remain stationary.Bearings1164 are rotationally-coupled to supportshaft1160, whilebearings1190 are rotationally-coupled to supportshaft1188.

FIGS. 31 and 32 depict an alternative embodiment of the present invention with counterbalancing.FIG. 31 presents a partially-exploded, isometric view of amotorized roller shade1220, whileFIG. 32 presents a sectional view along the longitudinal axis.Motorized roller shade1220 includes ashade tube1232 with aslot1233 to facilitate wireless signal transmission, a motor/controller unit1240, and apower supply unit1280. Generally, the motor/controller unit1240 includes aDC gear motor1255 with aDC motor1250 and an integral motorgear reducing assembly1252, acircuit board housing1244 attached to the fixedsupport shaft1260, atorque transfer coupling1273 that is attached to the output shaft of theDC gear motor1255 and theshade tube1232, and that also functions as a rotating perch, a fixedperch1256 attached to theDC gear motor1255, and acounterbalance spring1265 that couples the rotating perch/torque transfer coupling1273 to the fixedperch1256.End cap1258, housing one ormore bearings1264, andend cap1286, housing one ormore bearings1290, are also attached to theshade tube1232. Thepower supply unit1280 includes the battery stack, and is attached to theshade tube1232; the fixedsupport shaft1288 is free-floating. Accordingly, during operation, the output shaft of theDC gear motor1255, as well as thepower supply unit1280, rotates with theshade tube1232, while the motor/controller unit1240 remains stationary.Bearings1264 are rotationally-coupled to supportshaft1260, whilebearings1290 are rotationally-coupled to supportshaft1288.

FIGS. 33 and 34 depict an alternative embodiment of the present invention with counterbalancing.FIG. 33 presents a partially-exploded, isometric view of amotorized roller shade1320, whileFIG. 34 presents a sectional view along the longitudinal axis.Motorized roller shade1320 includes ashade tube1332 with aslot1333 to facilitate wireless signal transmission, a motor/controller unit1340, and apower supply unit1380. Generally, the motor/controller unit1340 includes aDC gear motor1355 with aDC motor1350 and an integral motorgear reducing assembly1352, acircuit board housing1344 attached to the fixedsupport shaft1360, atorque transfer coupling1373 that is attached to the output shaft of theDC gear motor1355 and theshade tube1332, and that also functions as a rotating perch, a fixedperch1356 attached to theDC gear motor1355, and acounterbalance spring1365 that couples the rotating perch/torque transfer coupling1373 to the fixedperch1356.End cap1358, housing one ormore bearings1364, andend cap1386, housing one ormore bearings1390, are also attached to theshade tube1332. Thepower supply unit1380 includes the battery stack, and is attached to the fixedsupport shaft1388; anadditional bearing1399 is also provided. Accordingly, during operation, the output shaft of theDC gear motor1355 rotates with theshade tube1332, while the motor/controller unit1340 and thepower supply unit1380 remain stationary.Bearings1364 are rotationally-coupled to supportshaft1360,bearings1390 are rotationally-coupled to supportshaft1388, while bearing1399 supports the shaft-like end portion of thepower supply unit1380.

Additionally, by enclosing the various components of the motorized roller shade within the shade tube, the blind or shade material can be extended to the ends of the tube, which advantageously reduces the width of the gap between the edge of the shade and the vertical surface of the opening in which the motorized roller shade is installed. For example, this gap can be reduced from 1 inch or more to about 7/16 of an inch or less on each side of the shade. The gaps can be the same width as well, which increases the ascetic appeal of the motorized roller shade. Additional light-blocking coverings, such as vertical tracks, are therefore not necessary.

Control Methods

Motorized roller shade20 may be controlled manually and/or remotely using a wireless or wired remote control. Generally, the microcontroller executes instructions stored in memory that sense and control the motion ofDC gear motor55, decode and execute commands received from the remote control, monitor the power supply voltage, etc. More than one remote control may be used with a singlemotorized roller shade20, and a single remote control may be used with more than onemotorized roller shade20.

FIG. 35 presents amethod400 for controlling amotorized roller shade20, according to an embodiment of the present invention. Generally,method400 includes amanual control portion410 and aremote control portion420. In one embodiment,method400 includes themanual control portion410, in another embodiment,method400 includes theremote control portion420, and, in a preferred embodiment,method400 includes both themanual control portion410 and theremote control portion420.

During themanual control portion410 ofmethod400, a manual movement of theshade22 is detected (412), a displacement associated with the manual movement is determined (414), and, if the displacement is less than a maximum displacement, theshade22 is moved (416) to a different position by rotating theshade tube32 using theDC gear motor55.

In one embodiment, the microcontroller detects a manual downward movement of theshade22 by monitoring a reed switch, while in an alternative embodiment, the microcontroller simply monitors the encoder. In a preferred embodiment, after the initial downward movement or tug is detected by the reed switch, the microcontroller begins to count the encoder pulses generated by the rotation of theshade tube32 relative to the fixedmotor shaft51. When the encoder pulses cease, the downward movement has stopped, and the displacement of theshade22 is determined and then compared to a maximum displacement. In one embodiment, the shade displacement is simply the total number of encoder pulses received by the microcontroller, and the maximum displacement is a predetermined number of encoder pulses. In another embodiment, the microcontroller converts the encoder pulses to a linear distance, and then compares the calculated linear distance to a maximum displacement, such as 2 inches.

In one example, the maximum number of encoder pulses is 80, which may represent approximately 2 inches of linear shade movement in certain embodiments. If the total number of encoder pulses received by the microcontroller is greater than or equal to 80, then the microcontroller does not energize theDC gear motor55 and theshade22 simply remains at the new position. On the other hand, if the total number of encoder pulses received by the microcontroller is less than 80, then the microcontroller moves theshade22 to a different position by energizing theDC gear motor55 to rotate theshade tube32. After the microcontroller determines that theshade22 has reached the different position, theDC gear motor55 is de-energized.

In preferred embodiments, the microcontroller maintains the current position of theshade22 by accumulating the number of encoder pulses since theshade22 was deployed in the known position. As described above, the known (e.g., open) position has an accumulated pulse count of 0, and the various intermediate positions each have an associated accumulated pulse count, such as 960, 1920, etc. When theshade22 moves in the downward direction, the microcontroller increments the accumulated pulse counter, and when theshade22 moves in the upward direction, the microcontroller decrements the accumulated pulse counter. Each pulse received from the encoder increments or decrements the accumulated pulse counter by one count. Of course, the microcontroller may convert each pulse count to a linear distance, and perform these calculations in units of inches, millimeters, etc.

In a preferred embodiment, limited manual downward movement of theshade22 causes the microcontroller to move the shade to a position located directly above the current position, such as 25% open, 50% open, 75% open, 100% open, etc. Each of these predetermined positions has an associated accumulated pulse count, and the microcontroller determines that theshade22 has reached the different position by comparing the value in the accumulated pulse counter to the accumulated pulse count of the predetermined position; when the accumulated pulse counter equals the predetermined position accumulated pulse count, theshade22 has reached the different position.

Other sets of predetermined positions are also contemplated by the present invention, such as 0% open, 50% open, 100% open; 0% open, 33% open, 66% open, 100% open; 0% open, 10% open, 20% open, 30% open, 40% open, 50% open, 60% open, 70% open, 80% open, 90% open, 100% open; etc. Advantageously, the accumulated pulse count associated with each position may be reprogrammed by the user to set one or more custom positions.

Manual upward movement of theshade22 may be detected and measured using an encoder that senses direction as well as rotation, such as, for example, an incremental rotary encoder, a relative rotary encoder, a quadrature encoder, etc. In other embodiments, limited upward movement of theshade22 causes the microcontroller to move the shade to a position located above the current position, etc.

During theremote control portion420 ofmethod400, a command is received (422) from a remote control, and theshade22 is moved (424) to a position associated with the command.

In preferred embodiments, the remote control is a wireless transmitter that has several shade position buttons that are associated with various commands to move theshade22 to different positions. The buttons activate switches that may be electro-mechanical, such as, for example, momentary contact switches, etc, electrical, such as, for example, a touch pad, a touch screen, etc. Upon activation of one of these switches, the wireless transmitter sends a message to themotorized roller shade20 that includes a transmitter identifier and a command associated with the activated button. In preferred embodiments, the remote control is pre-programmed such that each shade position button will command the shade to move to a predetermined position. Additionally, remote control functionality may be embodied within a computer program, and this program may be advantageously hosted on a wireless device, such as an iPhone. The wireless device may communicate directly with themotorized roller shade20, or though an intermediate gateway, bridge, router, base station, etc.

In these preferred embodiments, themotorized roller shade20 includes a wireless receiver that receives, decodes and sends the message to the microcontroller for further processing. The message may be stored within the wireless receiver and then sent to the microcontroller immediately after decoding, or the message may be sent to the microcontroller periodically, e.g., upon request by the microcontroller, etc. One preferred wireless protocol is the Z-Wave Protocol, although other wireless communication protocols are contemplated by the present invention.

After the message has been received by the microcontroller, the microcontroller interprets the command and sends an appropriate control signal to theDC gear motor55 to move the shade in accordance with the command. As discussed above, theDC gear motor55 andshade tube32 rotate together, which either extends or retracts theshade22. Additionally, the message may be validated prior to moving the shade, and the command may be used during programming to set a predetermined deployment of the shade.

For example, if the accumulated pulse counter is 3840 and theshade22 is 0% open, receiving a 50% open command will cause the microcontroller to energize theDC gear motor55 to move theshade22 upwards to this commanded position. As theshade22 is moving, the microcontroller decrements the accumulated pulse counter by one count every time a pulse is received from the encoder, and when the accumulated pulse counter reaches 1920, the microcontroller de-energizes theDC gear motor55, which stops theshade22 at the 50% open position. In one embodiment, if a different command is received while theshade22 is moving, the microcontroller may stop the movement of theshade22. For example, if theshade22 is moving in an upward direction and a close (0% open) command is received, the microcontroller may de-energize theDC gear motor55 to stop the movement of theshade22. Similarly, if theshade22 is moving in a downward direction and a 100% open command is received, the microcontroller may de-energize theDC gear motor55 to stop the movement of theshade22. Other permutations are also contemplated by the present invention, such as moving theshade22 to the predetermined position associated with the second command, etc.

In a preferred embodiment, a command to move the shade to the 100% open position resets the accumulated pulse counter to 0, and the microcontroller de-energizes theDC gear motor55 when the encoder pulses cease. Importantly, an end-of-travel stop, such asbottom bar28, stops24 and26, and the like, engage corresponding structure on the mounting brackets when theshade22 has been retracted to the 100% open position. This physical engagement stops the rotation of theshade tube32 and stalls theDC gear motor55. The microcontroller senses that the encoder has stopped sending pulses, e.g., for one second, and de-energizes theDC gear motor55. When theshade22 is moving in the other direction, the microcontroller may check an end-of-travel pulse count in order to prevent theshade22 from extending past a preset limit.

In other embodiments, the movement of theshade22 may simply be determined using relative pulse counts. For example, if the current position of theshade22 is 100% open, and a command to move theshade22 to the 50% open position is received, the microcontroller may simply energize theDC gear motor55 until a certain number of pulses have been received, by the microcontroller, from the encoder. In other words, the pulse count associated with predetermined position is relative to the predetermined position located directly above or below, rather than the known position.

For the preferred embodiment, programming amotorized roller shade20 to accept commands from a particular remote control depicted inFIGS. 36 and 43, while programming or teaching themotorized roller shade20 to deploy and retract theshade22 to various preset or predetermined positions, such as open, closed, 25% open, 50% open, 75% open, etc., is depicted inFIGS. 38 to 42. Other programming methodologies are also contemplated by the present invention.

In other embodiments, a brake may be applied to themotorized roller shade20 to stop the movement of theshade22, as well as to prevent undesirable rotation or drift after theshade22 has been moved to a new position. In one embodiment, the microcontroller connects the positive terminal of theDC gear motor55 to the negative terminal ofDC gear motor55, using one or more electro-mechanical switches, power FETS, MOSFETS, etc., to apply the brake. In another embodiment, the positive and negative terminals of theDC gear motor55 may be connected to ground, which may advantageously draw negligible current. In a negative ground system, the negative terminal of theDC gear motor55 is already connected to ground, so the microcontroller only needs to connect the positive terminal of theDC gear motor55 to ground. Conversely, in a positive ground system, the positive terminal of theDC gear motor55 is already connected to ground, so the microcontroller only needs to connect the negative terminal of theDC gear motor55 to ground.

Once the positive and negative terminals of theDC gear motor55 are connected, as described above, any rotation of theshade tube32 will cause theDC gear motor55 to generate a voltage, or counter electromotive force, which is fed back into theDC gear motor55 to produce a dynamic braking effect. Other braking mechanisms are also contemplated by the present invention, such as friction brakes, electro-mechanical brakes, electro-magnetic brakes, permanent-magnet single-face brakes, etc. The microcontroller releases the brake after a manual movement of theshade22 is detected, as well as prior to energizing theDC gear motor55 to move theshade22.

In an alternative embodiment, after theshade22 has been moved to the new position, the positive or negative terminal of theDC gear motor55 is connected to ground to apply the maximum amount of braking force and bring theshade22 to a complete stop. The microcontroller then connects the positive and negative terminals of theDC gear motor55 together via a low-value resistor, using an additional MOSFET, for example, to apply a reduced amount of braking force to theshade22, which prevents theshade22 from drifting but allows the user to tug theshade22 over long displacements without significant resistance. In this embodiment, the brake is not released after the manual movement of the shade is detected in order to provide a small amount of resistance during the manual movement.

One example of amotorized roller shade20 according to various embodiments of the present invention is described hereafter. Theshade tube32 is an aluminum tube having an outer diameter of 1.750 inches and a wall thickness of 0.062 inches.Bearings64 and90 each include two steel ball bearings, 30 mm OD×10 mm ID×9 mm wide, that are spaced 0.250″ apart. In other words, a total of four ball bearings, two at each end of themotorized roller shade20, are provided.

TheDC gear motor55 is a Bühler DC gear motor 1.61.077.423, as discussed above. Thebattery tube82 accommodates 6 to 8 D-cell alkaline batteries, and supplies voltages ranges from 6 V to 12 V, depending on the number of batteries, shelf life, cycles of the shade tube assembly, etc. Theshade22 is a flexible fabric that is 34 inches wide, 60 inches long, 0.030 inches thick and weighs 0.100 lbs/sq. ft, such as, for example, Phifer Q89 Wicker/Brownstone. An aluminum circularly-shapedcurtain bar28, having a diameter of 0.5 inches, is attached to theshade22 to provide taughtness as well as an end-of-travel stop. Thecounterbalance spring63 is a clock spring that provides 1.0 to 1.5 in-lb of counterbalance torque to theshade22 after it has reached 58 inches of downward displacement. In this example, the current drawn by the Bühler DC gear motor ranges between 0.06 and 0.12 amps, depending on friction.

FIGS. 36 to 45 present operational flow charts illustrating preferred embodiments of the present invention. The functionality illustrated therein is implemented, generally, as instructions executed by the microcontroller.FIG. 36 depicts a “Main Loop”430 that includes a manual control operational flow path, a remote control operational flow path, and a combined operational flow path.Main Loop430 exits to various subroutines, including subroutine “TugMove”440 (FIG. 37), subroutine “Move25”450 (FIG. 38), subroutine “Move50”460 (FIG. 39), subroutine “Move75470” (FIG. 40), subroutine “MoveUp”480 (FIG. 41), and subroutine “MoveDown”490 (FIG. 42), which return control toMain Loop430. Subroutine “Power-Up”405 (FIG. 43) is executed upon power up, and then exits toMain Loop430. Subroutine “Hardstop”415 (FIG. 44) is executed when a hard stop is, and then exits toMain Loop430. Subroutine “Low Voltage”425 (FIG. 45) is executed when in low voltage battery mode, and then exits tosubroutine MoveUp480.

FIG. 36 depicts theMain Loop430. Atstep3605, it is determined whether a message has been detected. If a message has not been detected, it is determined atstep3610 whether the tug timer has expired and, if not, the shade tube is monitored atstep3615. If the tug timer has expired, the dynamic brake is applied atstep3620. If a message is detected instep3605, a determination is made instep3625 as to whether a valid transmitter is stored in memory. If a valid transmitter is not stored in memory,step3630 determines whether the transmitter program mode timer has expired and, if so, control is returned tostep3605. If the transmitter program mode timer has not expired, the signal is monitored for five seconds instep3635 to determine at step3640 whether the user has pressed new transmitter for more than five seconds. If the user has pressed new transmitter for more than five seconds, the transmitter is placed in permanent memory and the flag is set to “NewLearn” instep3645. If the user has not pressed new transmitter for more than five seconds, control is returned tostep3605.

If it is determined instep3625 that a valid transmitter is stored in memory, decodebutton code step3650 begins. Instep3655, it is determined whether the “Up” button is detected; if so control flows tosubroutine MoveUp480, otherwise flow continues to step3660, where it is determined whether the “Down” button is detected. If the Down button is detected,subroutine MoveDown490 is invoked; otherwise, flow continues to step3665, where it is determined if the “75%” button is detected, in whichcase subroutine Move75470 begins. If the 75% button is not detected, it is determined instep3670 if the “50%” button is detected. If so,subroutine Move50460 is invoked and, if not, it is determined instep3675 if the “25%” button is detected, in whichcase subroutine Move25450 begins. If the “25%” button is not detected, flow continues to step3615, as well as to step3605 if in manual control.

Instep3680, it is determined whether the “LearnLimit,” Learn25,” “Learn50,” or “Learn75” flag is set and, if so, flow returns to step3605 to monitor for messages. If not, it is determined instep3685 whether a tug has occurred in the shade. If a tug has occurred, the dynamic brake is released atstep3690 and flow then continues on to subroutine TugMove440 (FIG. 37); otherwise, flow continues to step3605 to monitor for messages.

FIG. 37 depictssubroutine TugMove440. Insubroutine TugMove440, position change is tracked instep3705, and a determination is made instep3710 if motion has stopped, in which case it is determined instep3715 whether the tug timer has expired. If the tug timer has not expired, and if shade displacement is not greater than 2 inches, which is determined instep3720, subroutine MoveUp480 (FIG. 41) is executed; if, however, shade displacement is greater than two inches, the dynamic brake is applied instep3735 and control is returned to MainLoop430 (FIG. 36). If the tug timer has expired and if shade displacement is greater than two inches, determined instep3725, the tug timer is started instep3730, and then control is returned toMainLoop430.

If the tug timer has expired and shade displacement is not greater than two inches, as determined instep3725, a determination is made instep3740 as to whether the shade is between the closed and 75% positions, in which case subroutine Move75470 (FIG. 40) is executed. If the shade is not between the closed and 75% positions, a determination is made instep3745 as to whether the shade is between the 75% and 50% positions, in which case subroutine Move50460 (FIG. 39) is executed. If the shade is not between the 75% and 50% positions, a determination is made instep3750 as to whether the shade is between the 50% and 25% positions, in which case subroutine Move25450 (FIG. 38) is executed; otherwise subroutine MoveUp480 (FIG. 41) is invoked.

FIG. 38 depictssubroutine Move25450. If the “NewLearn” flag is determined to be set instep3802, subroutine MoveUp480 (FIG. 41) is executed. Otherwise, it is determined instep3804 whether the shade is a the 25% limit and, if so, the five second push button timer begins instep3806, after which it is determined instep3808 if the 25% button has been pressed for five seconds or more; if the 25% button has not been pressed for five seconds or more, it is determined instep3810 whether the 25% button is still being pressed and, if not, control returns to the MainLoop430 (FIG. 36). If, however, the 25% button is still being pressed, flow loops back to step3808 to again determine whether the 25% button has been pressed for five seconds or longer. When the 25% button has been pressed for five seconds or more, it is determined instep3812 if the Learn25 flag is set and, if yes, the current position is set as the 25% position instep3814. Then, instep3816, the shade is moved to up hard stop and the counts are reset, the Learn25 flag is reset instep3818, and control returns to theMainLoop430.

If it is determined instep3812 that the Learn25 flag is not set, instep3820 the shade moves down two inches and returns, and it is determined, instep3822, whether the user is still pressing the 25% button. When the user stops pressing the 25% button, a shade tug is monitored instep3824 and, when received,step3826 determines whether a valid transmission is detected. Once a valid transmission is detected, it is determined instep3828 if a tug was detected and, if a tug is detected, flags Learn25, Learn50, Learn75, and LearnLimit are set in step3830, and control returns to theMainLoop430. If a tug is not detected instep3828, however, control returns to theMainLoop430.

Returning to step3804, if it is determined in that step that the shade is not at the 25% limit, it is determined instep3832 whether the Learn25 flag is set and, if it is, the five second timer begins instep3806, as discussed above. If the Learn25 flag is not set, however, it is determined instep3834 if the shade is higher than the 25% position. If the shade is higher than the 25% position, the shade is moved in the downward direction toward the 25% position instep3836, and it is determined instep3838 if the shade is moving; if the shade is not moving, control returns to theMainLoop430. As the shade is moved downward toward the 25% position instep3836, it is determined, instep3842, whether the 25% Button is being pressed and, if yes, it is determined whether the shade is moving instep3838, described above. If, however, the 25% Button is not being pressed, it is determined, instep3844, if the Up button is being pressed, in which case, shade movement is stopped instep3846 and control returns to theMainLoop430. If the Up button is not pressed, it is determined instep3848 whether the Down, 50%, or 75% button is being pressed, in which case control returns to theMainLoop430; otherwise, it is determined instep3840 if the shade is still moving and, if so, the shade continues to move down and a determination is again made as to whether the 25% button is pressed, as described above forsteps3836 and3842. If the shade is not moving, control returns to theMainLoop430.

Referring again to step3834, if it is determined that the shade position is not higher than 25%, the shade is moved in the upward direction toward the 25% position instep3850. It is determined instep3852 if the 25% Button is being pressed and, if yes, it is determined, instep3854, whether the shade is moving. If the shade is moving, the determination of whether the 25% Button is being pressed continues instep3852; if the shade is not moving, control returns to theMainLoop430. If it is determined instep3852 that the 25% Button is not being pressed, it is determined, instep3856, if the Down button is pressed and, if it is, shade movement is stopped instep3858 and control returns to theMainLoop430. If, however, the Down button is not being pressed, it is determined, viastep3860, whether Up, 50%, or 75% buttons are being pressed; if so, control returns to theMainLoop430, otherwise it is determined instep3862 whether the shade is still moving and, if it is, the 25% button is monitored insteps3850 and3852 as described above. If the shade is not moving, control returns to theMainLoop430.

FIG. 39 depictssubroutine Move50460. If the NewLearn flag is set, as determined instep3902, subroutine MoveUp480 (FIG. 41) is invoked; otherwise it is determined instep3904 whether the shade is at the 50% limit and, if it is not,step3906 determines whether the Learn50 flag is set. If the Learn50 flag is not set,step3908 determines whether the shade position is higher than 50% and, if not, the shade is moved in the upward direction toward the 50% position instep3910. If the 50% button is being pressed, as determined instep3912, and if the shade is moving, as determined instep3914, movement of the shade in the upward direction continues. If the 50% button is being pressed, but the shade is not moving, as determined instep3914, control returns to the MainLoop430 (FIG. 36). If it is determined instep3912 that the 50% button is not being pressed, it is determined instep3916 whether the Down button is pressed and, if it is, shade movement is stopped instep3918 and control returns to theMainLoop430. If the Down button is not pressed, however, it is determined instep3920 whether the Up, 25%, or 75% buttons are pressed and, if so, control returns to theMainLoop430 or, if not,step3922 determines whether the shade is still moving and, if it is not, control returns to theMainLoop430; if the shade is still moving, whether the 50% button is being pressed is monitored insteps3910 and3912 described above.

Returning to discussion ofstep3908, if the shade position is higher than 50%, the shade is moved in the downward direction toward the 50% position instep3924, and step3926 monitors whether the 50% button is being pressed. If the 50% button is being pressed and if the shade is still moving, as determined instep3928, the downward motion of the shade continues; if the shade is determined to not be moving instep3928, however, control returns to theMainLoop430. If the 50% button is not being pressed, it is determined instep3930 if the Up button is pressed and, if it is, shade movement is stopped instep3932 and control returns to theMainLoop430. If the Up button is not pressed, it is determined instep3934 whether the Down, 25%, or 75% button is being pressed and, if yes, control returns to theMainLoop430; otherwise,step3936 determines if the shade is still moving. If the shade is still moving, the monitoring of the 50% button being pressed resumes atsteps3924 and3926, otherwise control returns to theMainLoop430.

Returning to step3906, if the Learn50 flag is set, or if the shade is determined instep3904 to be at the 50% limit, the five second push button timer begins instep3940, and step3942 monitors whether the 50% button has been pressed for five seconds or more. If the 50% button has not been pressed for five seconds or more,step3944 determines whether the 50% button is still being pressed and, if so,step3942 continues to monitor for whether the 50% button has been pressed for five seconds or more. If the 50% button has been pressed for five seconds or more, it is determined instep3946 whether the Learn50 flag is set and, if it is set, the current position is set as the 50% position instep3948, the shade is moved to the up hard stop and the counts are reset instep3950, the Learn50 flag is reset instep3952, and control returns to theMainLoop430. If, however, the Learn50 flag is not set, as determined instep3946, instep3954 the shade moves down two inches and returns, and step3956 monitors until the 50% button is no longer pressed, at whichpoint step3958 monitors for a shade tug.Step3960 determines whether a valid transmission is detected and, if so,step3962 determines if a tug was detected, in which case the Learn50 flag is set, the Learn25, Learn75 and LearnLimit flags are reset instep3964, and control returns to theMainLoop430. If a tug was not detected, however, control simply returns to theMainLoop430 without performingstep3964.

FIG. 40 depictssubroutine Move75470. If the NewLearn flag is set, as determined instep4002, subroutine MoveUp480 (FIG. 41) is invoked; otherwise it is determined instep4004 whether the shade is at the 75% limit and, if it is not,step4006 determines whether the Learn75 flag is set. If the Learn75 flag is not set,step4008 determines whether the shade position is higher than 75% and, if not, the shade is moved in the upward direction toward the 75% position instep4010. If the 75% button is being pressed, as determined instep4012, and if the shade is moving, as determined instep4014, movement of the shade in the upward direction continues. If the 75% button is being pressed, but the shade is not moving, as determined instep4014, control returns to the MainLoop430 (FIG. 36). If it is determined instep4012 that the 75% button is not being pressed, it is determined instep4016 whether the Down button is pressed and, if it is, shade movement is stopped instep4018 and control returns to theMainLoop430. If the Down button is not pressed, however, it is determined instep4020 whether the Up, 25%, or 50% buttons are pressed and, if so, control returns to theMainLoop430 or, if not,step4022 determines whether the shade is still moving and, if it is not, control returns to theMainLoop430; if the shade is still moving, whether the 75% button is being pressed is monitored insteps4010 and4012 described above.

Referring again to step4008, if the shade position is higher than 75%, the shade is moved in the downward direction toward the 75% position instep4024, and step4026 monitors whether the 75% button is being pressed. If the 75% button is being pressed and if the shade is still moving, as determined instep4028, the downward motion of the shade continues; if the shade is determined to not be moving instep4028, however, control returns to theMainLoop430. If the 75% button is not being pressed, it is determined instep4030 if the Up button is pressed and, if it is, shade movement is stopped instep4032 and control returns to theMainLoop430. If the Up button is not pressed, it is determined instep4034 whether the Down, 25%, or 50% button is being pressed and, if yes, control returns to theMainLoop430; otherwise,step4036 determines if the shade is still moving. If the shade is still moving, the monitoring of the 75% button being pressed resumes atsteps4024 and4026, otherwise control returns to theMainLoop430.

Instep4006, if the Learn75 flag is set, or if the shade is determined instep4004 to be at the 75% limit, the five second push button timer begins instep4040, and step4042 monitors whether the 75% button has been pressed for five seconds or more. If the 75% button has not been pressed for five seconds or more,step4044 determines whether the 75% button is still being pressed and, if so,step4042 continues to monitor for whether the 75% button has been pressed for five seconds or more. If the 75% button has been pressed for five seconds or more, it is determined instep4046 whether the Learn75 flag is set and, if it is set, the current position is set as the 75% position instep4048, the shade is moved to the up hard stop and the counts are reset instep4050, the Learn75 flag is reset instep4052, and control returns to theMainLoop430. If, however, the Learn75 flag is not set, as determined instep4046, instep4054 the shade moves down two inches and returns, and step4056 monitors until the 75% button is no longer pressed, at whichpoint step3958 monitors for a shade tug.Step4060 determines whether a valid transmission is detected and, if so,step4062 determines if a tug was detected, in which case the Learn75 flag is set, the Learn25, Learn50 and LearnLimit flags are reset in step4064, and control returns to theMainLoop430. If a tug was not detected, however, control simply returns to theMainLoop430 without performing step4064.

FIG. 41 depictssubroutine MoveUp480. It is determined whether the shade is at the Up limit instep4102. If the shade is at the Up limit, it is determined instep4104 if the NewLearn flag is set, in which case the shade is moved down two inches and the NewLearn flag is cleared instep4106, after which the shade is moved to the Up limit instep4110, which also clears the NewLearn flag. If the NewLearn flag is not set, it is determined instep4108 if the LearnLimit, Learn25, Learn50, or Learn 75 flag is set, in which case control returns to theMainLoop430. If none of the LearnLimit, Learn25, Learn50, or Learn 75 flags are set, the five second push button timer begins instep4112. Instep4114, it is determined whether the Up button has been pressed for five seconds or more and, if not,step4116 determines if the Up button is still being pressed; if not, control returns to theMainLoop430; if so,step4114 continues to monitor whether the Up button has been pressed for five seconds or more, after which the shade is moved to the 75% position instep4118. A shade tug is monitored for instep4120, and when a valid transmission is detected instep4122, it is determined instep4124 whether a tug was detected and, if not, control returns to theMainLoop430; otherwise, it is determined instep4126 whether the valid transmission was from the Up or Down button of a learned or unlearned transmitter, in which case the five second learn/delete timer begins instep4128. Instep4130, it is determined whether the button has been pressed for five seconds or longer and, if not,step4132 determines if the button is still being pressed; if not, control returns to theMainLoop430, otherwise step4130 continues to monitor whether the button has been pressed for five seconds or longer, at which point it is determined instep4134 if the button pressed was the Up button and, if it was, the transmitter is placed in permanent memory instep4136. If the button pressed was not the Up button, the transmitter is deleted from permanent memory instep4138. After the transmitter is added to or deleted from permanent memory instep4136 or4138, respectively, the shade is moved to the Up limit and stopped instep4140, and control returns to theMainLoop430.

Referring again to step4110, after the shade is moved to the Up limit and the NewLearn flag is cleared, it is determined instep4142 whether the Up button is being pressed; if it is, a determination is made isstep4144 as to whether the shade is moving and, if it is, the shade continues to move to the Up limit and the NewLearn flag is cleared. If the Up button is not being pressed, however, it is determined instep4146 whether the Down button is pressed and, if it is, shade movement is stopped instep4148 and control returns to theMainLoop430. If the Down button is not being pressed,step4150 determines whether the 25%, 50% or 75% button is being pressed and, if yes, control returns to theMainLoop430; otherwise, it is determined instep4152 if the shade is still moving, in which case the monitoring of the Up button being pressed continues insteps4110 and4142. If the shade is not still moving, however, control returns to theMainLoop430.

FIG. 42 depictssubroutine MoveDown490. If the NewLearn flag is determined instep4202 to be set, subroutine MoveUp480 (FIG. 41) is executed; otherwise, it is determined instep4204 whether the shade is at the Down limit and, if it is not, and if the LearnLimit flag is not set, as determined instep4206, the shade is moved to the Down limit instep4208. If the LearnLimit flag is set, or if the shade is at the Down limit, the five second push timer begins, instep4210. Instep4212, it is determined whether the Down button has been pressed for five or seconds or more and, if it has not,step4214 determines if the Down button is still pressed. If the Down button is not still being pressed, control returns to the MainLoop430 (FIG. 36); otherwise step4212 monitors for whether the Down button has been pressed for five or seconds or more and, if so,step4216 determines whether the LearnLimit flag is set; if the LearnLimit flag is set, the current position of the shade is set as the Down limit instep4218, the shade is moved up to the hard stop and the counts are reset instep4220, the LearnLimit flag is reset instep4222, and control returns to theMainLoop430. If it is determined instep4216 that the LearnLimit flag is not set, the shade moves up two inches and return instep4224, after which it is determined instep4226 if the user is still pressing the Down button and, if not, a shade tug is monitored for instep4228. Instep4230, it is determined whether a valid transmission is detected and, instep4232, whether a tug was detected, in which case the LearnLimit flag is set and the Learn25, Learn50, and Learn75 flags are reset; otherwise control returns to theMainLoop430.

Referring again to step4208, in which the shade is moved down, it is determined instep4236 whether the Down button is being pressed and, if it is, whether the shade is still moving instep4238. If it is determined instep4238 that the shade is not moving, control is returned to theMainLoop430. If it is determined instep4236 that the Down button is not being pressed,step4240 determines whether the Up button is being pressed and, if it is, shade movement is stopped instep4242 and control returns to theMainLoop430. If the Up button is not being pressed, it is determined instep4244 whether the 25%, 50% or 75% buttons are being pressed; if this is the case, control returns to theMainLoop430, otherwise it is determined instep4246 whether the shade is still moving and, if it is, the monitoring of the Down button continues insteps4208 and4236. If the shade is not still moving, control returns to theMainLoop430.

FIG. 43 depicts subroutine Power-Up405. Instep4305, transmitter program mode is opened. Instep4310, it is determined whether a valid transmitter is detected. When a valid transmitter is detected, it is determined instep4315 whether the transmitter is stored in permanent memory; if not, it is determined instep4320 if the transmitter program mode timer has expired, in whichcase step4310 continues to monitor for a valid transmitter detection. If the transmitter program mode timer has not expired, however, the signal is measured for five seconds instep4325 and it is determined instep4330 whether the user pressed New Transmitter for more than five seconds. If New Transmitter has not been pressed for more than five seconds, a valid transmitter detection is monitored for instep4310; otherwise the transmitter is placed in permanent memory instep4335 and it is determined instep4340 if the shade has moved to the Hard Stop, in which case the shade is moved to the Down limit instep4345 and control continues to theMainLoop430. If the shade has not moved to the Hard Stop, the shade is moved up to find the Hard Stop instep4350 and, if the shade traveled up less than two inches, as determined instep4355, the shade is moved down two inches and returns, as shown in step4360, after which the dynamic brake is applied instep4365. If the shade did not travel up less than two inches, i.e., if the shade traveled up two inches or more, the dynamic brake is applied instep4365 without moving the shade down two inches and returning it, as is done in step4360.

FIG. 44 depictssubroutine Hardstop415. Instep4402, the shade stops moving and, instep4404, it is determined whether a hardstop has been requested; if not, control returns to MainLoop430 (FIG. 36), otherwise it is determined instep4406 if the LearnLimit flag is set. If the LearnLimit flag is not set, it is determined instep4408 if the Learn25 flag is set, in which case the new 25% setpoint is stored instep4410; otherwise, it is determined, instep4412 if the Learn50 flag is set, in which case the new 50% setpoint is stored instep4414; otherwise it is determined, instep4416 if the Learn75 flag is set, in which case the new 75% setpoint is stored instep4418. If none of the LearnLimit, Learn25, Learn50, or Learn75 flags are set, or after the new 25%, 50%, or 75% setpoint is stored insteps4410,4414, or4418, respectively, the LearnLimit, Learn25, Learn50, and Learn75 flags are cleared, as applicable, instep4420.

If it is determined instep4406 that the LearnLimit flag is set, a new lower limit is stored instep4425, after which it is determined instep4430 whether a 25% setpoint has been learned; if not, a new 25% setpoint is calculated instep4432, and it is thereafter determined, instep4434, if a 50% setpoint has been learned. If a 50% setpoint has not been learned, a new 50% setpoint is calculated instep4436, and it is then determined instep4438 if a 75% setpoint has been learned. If a 75% setpoint has not been learned, a new 75% setpoint is calculated instep4440, and flow continues to step4420, where the LearnLimit, Learn25, Learn50, and/or Learn75 flags are cleared, as described above. After the applicable flags are cleared instep4420, it is determined instep4450 whether the shade is drifting down due to heavy fabric, for example, in which case the shade is driven to the top instep4455. Instep4460, it is determined whether the shade has stopped moving for one second, in which control returns to theMainLoop430; otherwise it is again determined whether the shade is drifting down instep4450.

FIG. 45 depictssubroutine LowVoltage425, in which it is determined, instep4502, if the shade is in Low Battery Voltage Mode; if not, it is determined instep4504 if the shade is one revolution plus 50 ticks from the top, in which case the timer is started instep4506. When it is determined, instep4508, that the shade is 50 ticks from the top, the timer is stopped instep4510, and it is determined, instep4512, whether the time is faster than any one of the times stored in permanent memory. If the time is faster than any one of the times stored in memory, the time is stored in permanent memory, the time is stored instep4514; thereafter, or otherwise, it is determined instep4516 if the time is slower than twice the average of all times stored in permanent memory and, if not, the count of consecutive slow cycles is cleared instep4518, brownout detection is disabled instep4520, and control returns to subroutine MoveUp480 (FIG. 41). If the time is slower than twice the average of all times stored in permanent memory, however, brownout detection is enabled instep4522, and it is determined, instep4524, if this was the tenth consecutive slow cycle; if not, the count of consecutive slow cycles is incremented instep4526 and control returns tosubroutine MoveUp480. In contrast, if this was the tenth consecutive slow cycle, LowVoltage Batter Mode4528 is invoked. Similarly, LowVoltage Batter Mode4528 is invoked based on the determination described above forstep4502.

Instep4530, it is determined, for Low Voltage Battery Mode, if the shade is at the top, e.g., is at zero (0) percent. If not, the shade is moved to the top instep4532; otherwise, it is determined instep4534 whether the 25%, 50%, 75%, or Down button has been pressed, in which case the shade is jogged down one-half (A) rotation instep4536, and is then moved to the top instep4532.

The many features and advantages of the invention are apparent from the detailed specification, and, thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and, accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the invention.

Claims (22)

What is claimed is:

1. A system for operating a roller shade comprising:

a roller configured to be attached to a shade;

a DC motor having a rated voltage, the DC motor operatively connected to the roller and configured to rotate the roller; and

a DC power source operatively connected to the DC motor to provide DC power to the DC motor at an average voltage,

wherein a maximum average voltage the DC power source can supply the DC motor is approximately half or less than half the rated voltage of the DC motor wherein the motor rotates with the roller.

2. A system for operating a roller shade comprising:

a roller configured to be attached to a shade;

a DC motor having a rated voltage, the DC motor operatively connected to the roller and configured to rotate the roller; and

a DC power source operatively connected to the DC motor to provide DC power to the DC motor at an average voltage,

wherein a maximum average voltage the DC power source can supply the DC motor is approximately half or less than half the rated voltage of the DC motor further comprising a shaft on which the roller is mounted and the shaft is configured to stay stationary and the roller rotates about the shaft.

3. The system ofclaim 2, wherein the connection between the DC motor and the roller includes a gear system.

4. The system ofclaim 3, wherein the gear system has between about a 40:1 and a 30:1 gear ratio.

5. The system ofclaim 3, wherein the gear system has between about a 40:1 and a 20:1 gear ratio.

6. The system ofclaim 5, wherein the maximum average voltage is about 9.6 volts and the rated voltage of the DC motor is about 24 volts.

7. The system ofclaim 5, wherein the maximum average voltage is about 4.8 volts and the rated voltage of the DC motor is about 24 volts.

8. The system ofclaim 5, wherein the maximum average voltage is 4.8 volts and the rated voltage of the DC motor is about 12 volts.

9. The system ofclaim 3, wherein the gear system includes a multistage planetary gear system.

10. The system ofclaim 2, wherein the maximum average voltage is between about 40% and about 20% of the rated voltage of the DC motor.

11. The system ofclaim 2, wherein the power source includes four to eight batteries.

12. The system ofclaim 11, wherein the batteries are C-cell, or D-cell batteries.

13. The system ofclaim 2, wherein the DC power source includes at least one of any of the following battery types: alkaline, zinc, lead acid, lithium and nickel.

14. The system ofclaim 2, wherein the DC power source is located within the roller.

15. The system ofclaim 2, wherein the roller is configured to rotate under either of the two following circumstances: the DC power source provides power to the DC motor and the shade is manually pulled.

16. The system ofclaim 2, wherein when a maximum amount of power from the DC power sources is applied to the DC motor, the motor runs significantly slower than a maximum rated speed of the DC motor.

17. The system ofclaim 16, wherein when a maximum amount of power from the DC power source is supplied to the DC motor, the DC motor runs at approximately half the DC motor's rated speed.

18. A method of operating a roller shade comprising:

supplying DC power to a DC motor wherein the supplied power is, on average, a voltage of approximately half or less than half of the rated voltage of the motor;

rotating at least one gear in a set of gears; and

rotating a tube connected to a shade when at least one of either the motor operates and the shade is manually pulled off of the roller, wherein the set of gears is part of a mechanical connection between the DC motor and the tube;

wherein the tube rotates fewer times than revolutions of an output shaft of the motor wherein the motor rotates with the tube.

19. The method ofclaim 18, further comprising: supplying the DC power to the DC motor at about 9.6 volts and the motor is rated for about 24 volts.

20. The method ofclaim 18, wherein the output shaft of the motor rotates about 40 times for each rotation of the tube.

21. The method ofclaim 18, wherein the DC power is supplied by a DC power source located within the tube.

22. The method ofclaim 18, wherein a gear system operatively connects an output of the DC motor to the roller, wherein the gear system has a sufficiently low enough gear ratio to allow manual movement of the shade without breaking the gear system.

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